The use of fourth generation ceramic as an orthopaedic biomaterial has proved to be a very efficient and has gained popularity for primary hip surgery in the last 8–10 years. Cumulative percentage probability of revision after 7 years for un-cemented CoC is 3.09% and for hybrid CoC is 2.00%, this compares favourably with traditional metal-on-UHMWPE un-cemented at 3.05% and hybrid at 2.35% (12th Annual Report - NJR, 2015). Such ceramic-on-ceramic hip prostheses are being implanted in ever younger, more active patients, and yet very few long-term large cohort retrieval studies are yet to be carried out due to the survivorship of the implants.

It has been seen in previous studies that levels of wear in ceramic-on-ceramic bearing surface can be of the order of 0.2 mm³/million cycles (Al-Hajjar, Fisher, Tipper, Williams, & Jennings, 2013). This is incredibly low when compared to studies that characterize wear in other bearing surface combinations. It has also been reported that an unusual stripe pattern of wear can occur in some in-vivo retrieved cups (Macdonald & Bankes, 2014) and it has further been postulated that this is caused by cup edge loading (Walter, Insley, Walter, & Tuke, 2004). The combined measurement challenge of stripe wear occurring at the edge of a low-wear ceramic-on-ceramic device is considerable, a solution to which is presented here. Current literature on wear measurement of such cases has been confined to in-vitro simulator studies and use of gravimetric measurement which by definition has limitations due to the lack of spacial characterisation.

This paper details a novel method for measuring edge-wear in CoC acetabular liners. The method has been employed in an in-vitro study where it has been benchmarked against gravimetric measurements. These liners were measured on a CMM to determine the volume of material loss. The measurements were conducted as a blinded post-wear study akin to measurement of retrieved components.

The most challenging part of this novel method was to create a reference geometry that replicates the free form edge surface of the ‘unworn’ cup using the residual post-wear surface. This was especially challenging due to the uncontrolled geometry at the cup edge and intersection of geometric features at this point. To achieve this, the geometry surrounding the wear patch was used to create a localized reference feature that minimised the effect of global form errors caused by hand polishing in the edge area. Furthermore, the reference geometry is compared with the measured surface to determine the linear penetration and volumetric wear loss. Result of this novel method can be seen in Fig 1. The findings have been compared to gravimetric results and a bar graph comparing two results can be seen in Fig 2.

Overall the accuracy of the method for this cohort was 0.03–0.2 mm³ when compared to gravimetric reference measurements. This compares very favourably with previously published wear measurement methods and gives confidence in the ability to measure such small measurement volumes over complex geometry.

Introduction

Metal-on-metal (MOM) total hip arthroplasty using large diameter femoral heads offer clinical advantages however the failure rates of these hips is unacceptably high. Retrieved hips have a wide range of wear rates of their bearing and taper surfaces and there is no agreement regarding the cause of failure.

Detailed visual inspection is the first step in the forensic examination of failed hip components and may help explain the mechanisms of failure. The aim of this study was to determine if there was a correlation between the results of detailed inspections and the volumetric wear of the bearing and taper surfaces of retrieved hips.

Background

The changes in surface roughness occurring during the wear process at the bearing surface are of great importance in trying to understand the failure mechanism of large head metal-on-metal hip replacements. The aim of the study is to identify and characterise the areal surface parameter variation between the worn and unworn areas. Surface topography variations at the bearing surface have an effect on the lubrication regime [1]. In vitro tests of these components have suggested a “self-polishing” of the surface [2]. Traditionally Ra has been used as a descriptor of surface texture. Considering the high standard of manufacturing to which these components are produced, Ra is not sufficient to describe surface morphology which requires spatial information which can only be achieved through the use of areal parameters.

Material loss at the head-stem taper junction may contribute to the high early failure rates of stemmed large head metal-on-metal (LH-MOM) hip replacements. We sought to quantify both wear and corrosion and by doing so determine the main mechanism of material loss at the taper. This was a retrospective study of 78 patients having undergone revision of a LH-MOM hip replacement. All relevant clinical data was recorded. Corrosion was assessed using light microscopy and scanning electron microscopy, and graded according to a well-published classification system. We then measured the volumetric wear of the bearing and taper surfaces. Evidence of at least mild taper corrosion was seen in 90% cases, with 46% severely corroded. SEM confirmed the presence of corrosion debris, pits and fretting damage. However, volumetric wear of the taper surfaces was significantly lower than that of the bearing surfaces (p = 0.015). Our study supports corrosion as the predominant mechanism of material loss at the taper junction of LH-MOM hip replacements. Although the volume of material loss is low, the ionic products may be more biologically active compared to the particulate debris arising from the bearing surfaces.

It has been speculated that high wear at the head-stem taper may contribute to the high failure rates reported for stemmed large head metal-on-metal (LH-MOM) hips. In this study of 53 retrieved LH-MOM hip replacements, we sought to determine the relative contributions of the bearing and taper surfaces to the total wear volume. Prior to revision, we recorded the relevant clinical variables, including whole blood cobalt and chromium levels. Volumetric wear of the bearing surfaces was measured using a coordinate measuring machine and of the taper surfaces using a roundness measuring machine. The mean taper wear volume was lower than the combined bearing surface wear volume (p = 0.015). On average the taper contributed 32.9% of the total wear volume, and in only 28% cases was the taper wear volume greater than the bearing surface wear volume. Despite contributing less to the total material loss than the bearing surfaces, the head-stem taper junction remains an important source of implant-derived wear debris. Furthermore, material loss at the taper is likely to involve corrosion and it is possible that the material released may be more biologically active than that from the bearing surface.

INTRODUCTION

There is increasing worldwide interest in the assessment of wear in explanted hip components. This is due is part to high profile failures of orthopaedic components in the US, whilst in the UK hip resurfacings have been experiencing a higher than expected failure rate. The reasons for these failures are not well understood, with data from the NJR suggesting the 43% of MoM resurfacing failures are unexplained.

Wear analysis is a vital tool in determining failure mechanisms and ultimately improving the longevity of joint replacements through improved design and manufacturing control. There are currently no relevant measurement standards for the evaluation of retrieved orthopaedic components. This paper will assess two of the most commonly used techniques namely roundness measurement and co-ordinate measurement. The advantages and disadvantages of both techniques are considered in this paper.